PLASTIC Packing and Column Internals - YOU CAN RELY ON US - Koch-Glitsch
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Introduction For more than 70 years, random packings in ceramic, metal, and plastic have been used successfully as an inexpensive but efficient means to increase a tower’s capacity and/or efficiency. The original Raschig Rings have been superseded by new generations of improved products. Today, Koch-Glitsch offers the widest spectrum of random packings available worldwide. For more demanding applications, structured packing offers even lower pressure drop and higher efficiency. Structured packing is offered in both standard- and high-capacity versions to meet any performance specification. There are numerous process advantages that can be realized by using packings in various applications. The predominant reasons for using tower packings are to reduce pressure drop throughout the column, to increase the capacity compared to trays at the same efficiency, and/or to reduce liquid holdup in the column. Plastic random packings are not as bulky as their ceramic equivalents and, therefore, offer higher capacity and lower pressure drop. From an engineering point of view, plastics are materials that will permanently deform when stress (force) is applied at common temperatures. The rate at which a plastic will deform depends on the amount of stress, temperature, and time. Compression at the bottom of a packed bed reduces the void fraction and can lead to increased pressure drop and premature flooding. Koch-Glitsch has developed a proprietary database of allowable operating loads for plastic packing based on creep modulus data that is used to ensure the structural integrity of your packed beds. This booklet provides information for quick sizing of packed columns using plastic structured and random packings. The charts provide hydraulic ratings and relative packing efficiencies (in terms of the KGa value for the absorption of CO2 into a standard caustic solution). In addition, Koch-Glitsch offers the hydraulic rating program, KG-TOWER® software, which may be downloaded from its website: www.koch-glitsch.com. Koch-Glitsch is unsurpassed in offering the widest range of sizes and styles of traditional and high performance plastic structured and random packings. To enable the process engineer to optimize the system for cost and performance, several sizes are offered within each packing family. As the packing size increases within the family, the packing offers greater capacity and lower pressure drop at the expense of GRP Flue Gas Condensing Scrubber. lower efficiency. Koch-Glitsch and its sister companies deliver innovative process and pollution control equipment designed to optimize plant operations and manage the constant changes in environmental standards. n State-of-the-art ceramic and plastic products from Koch Knight are applied in demanding corrosive applications. n With over 35 years’ experience and 400 plants in operation, Eta Process Plant is the world’s leading supplier of turnkey deaeration plants. n Combined with Koch-Glitsch, Koch Specialty Plant Services offers the single supplier/installer benefits of turnkey solutions, which provides faster, safer revamps with minimum downtime. n Precision membrane technologies from Koch Membrane Systems include ultrafiltration and reverse osmosis (RO) membrane systems to help purify the world’s water. 2
Column Internals Koch-Glitsch plastic column internals are available in both thermoplastic and thermoset (e.g. Fiberglass-Reinforced Plastic – FRP) materials. Occasionally, thermoplastic internals have different temperature limits than packing of the same material. Koch-Glitsch has an unsurpassed knowledge in recognizing these instances and can provide designs specific to any application. FRP column internals use different designs than thermoplastic internals. FRP has better structural properties but greater fabrication restrictions. The Koch-Glitsch standard thermoset is one of the DERAKANE® brand resins, although other resins are available to suit a wide range of chemical and thermal requirements. Model TP 286 Thermoplastic Trough Model TS 236 FRP Liquid Distributor Model TP 804 Support Grid, Distributor with Drip Tubes. with Side Orifices. PTFE/Carbon-Carbon. Koch-Glitsch process engineers will help select the appropriate style of packing and match that packing with the optimum tower internals to create the INTALOX® Packed Tower System that best satisfies your specific requirements. For more information on liquid and vapor distribution technology as well as other column internals in thermoplastic or FRP, consult our brochure, Plastic Packed Tower Internals (KGPTIG-1). Materials of Construction Plastic packings are often preferred because of their lightweight construction Available Materials and resistance to breakage. The availability of numerous types of plastic ■ General grade polypropylene resins provides the designer with a broad range of chemical and thermal ■ LTHA polypropylene resistant materials. Koch-Glitsch plastic packings are made in a wide variety of ■ LTHA polypropylene thermoplastic materials. Most of the Koch-Glitsch packings are available in the (10% glass filled) materials shown in the Available Materials list. Other plastics are available by ■ High density polyethylene special request. ■ Low density polyethylene ■ PVC The mechanical strength of a plastic material decreases over time. Temperature ■ CPVC limits for long-term service life depend on the load the packing must bear from ■ PVDF its own weight and from liquid holdup. The maximum operating temperature ■ E-CTFE depends on system environment, packing size, and bed height. In general, ■ ETFE deep packed beds, weaker packing shapes, and high liquid loads result in ■ ETFE (25% glass filled) lower temperature limits. Packed heights can be increased by using specially ■ PFA formulated filled resins. Typical fillers include glass fibers, carbon fibers, and chalk. Contact Koch-Glitsch to determine a specific load limit for a particular Koch-Glitsch product at a certain temperature. 3
Applications Plastic packings are used in Absorbers ■ CO2 absorption corrosive applications with low to ■ SO2, HCL, and HF absorption or stripping ■ Chlorine absorption in water or caustic moderate operating temperature ■ Chlorine dioxide absorption ■ Hydrogen sulfide and mercaptan removal and can offer an economic ■ Air pollution control scrubbers Fume scrubbing advantage over metal materials. ■ ■ Odor control Where temperatures permit, ■ VOC removal plastic packings perform better Degassing ■ Decarbonation than ceramic packings and are ■ Deaeration often less expensive than metals, Water treatment ■ Waste water treatment particularly when exotic metals and ■ Drinking water preparation Fish farming alloys are required. Consequently, ■ plastic packings are used mainly in Heat transfer ■ Humidification absorption, scrubbing, stripping, ■ Dehumidification ■ Direct contact cooler and heat transfer services. ■ Water chiller Super INTALOX® Saddles random packing n Enhance internal gas and liquid distribution n Scalloped edges − Provide more interstitial transfer points per unit of volume than standard saddle packings − Immobilize the packing within the bed, which reduces settling n Saddle shape ensures complete randomness of packed bed Nominal size 1 2 3 Void fraction % 90 93 94 Bulk weight lb/ft3 5.2 3.8 3.1 (polypropylene) kg/m3 83 61 50 4
FLEXIRING® random packing An economical and versatile industry standard with well-known performance characteristics. n Openings in cylinder provide more use of internal mass transfer area and lower pressure drop compared to Raschig Rings n Extensively used; therefore, performance is widely known n Industry standard for many designers n 2 in [50 mm] and 4 in [100 mm] versions are available with extra internal vanes to produce higher efficiency compared to the standard versions High Performance Nominal size 5/8 1 1.5 2 3.5 2 4 mm 16 25 38 50 90 50 100 inch 5/8 1 1.5 2 3.5 2 4 Void fraction % 87 92 91 93 95 93 96 Bulk weight lb/ft 3 5.9 4.4 4.3 3.8 2.7 3.8 2.2 (polypropylene) kg/m3 95 71 70 60 43 60 36 6
CASCADE MINI-RINGS® random packing High capacity and low pressure drop with high mechanical strength that allows use in deep beds. n Achieves better efficiency and capacity than FLEXIRING® random packing as a result of the low aspect ratio n In a packed bed, a significant portion of the rings lie with their axes nearly vertical n The preferred orientation exposes both the interior and exterior surfaces to liquid and vapor flow n Geometry provides more efficient use of the packing surface n Largest opening is in the direction of vapor flow, resulting in lower pressure drop and higher capacity n Orientation with cylindrical axis in the vertical position increases the mechanical strength of the packed bed Nominal 1A size 2 2A 3A Void fraction % 97 97 97 98 Bulk weight lb/ft 3 3.3 2.7 2.9 2.5 (polypropylene) kg/m3 53 43 46 40 8
BETA RING® random packing High vapor capacity and efficiency with high liquid handling capacity. n Strategic placement of slots and tabs provides an extremely effective use of packing surface area n Variation in the length of the internal tabs ensures high efficiency and optimal distribution n Uninterrupted flow of gas and liquid n Provides additional drip points to enhance liquid film surface renewal for improved mass and heat transfer n Well suited for applications where low pressure drop and high liquid handling capacity are important Nominal 1 size 2 3 Void fraction % 94 94 96 Bulk weight lb/ft 3 3.3 3.4 2.4 (polypropylene) kg/m3 53 54 38 Seawater Deaeration Seawater can be injected into hydrocarbon reservoirs to maintain pressure and production. It is desirable to remove oxygen from the seawater because it promotes corrosion and growth of certain bacteria that produce hydrogen sulfide. The oxygen can be removed using a stripping gas or vacuum system. ETA Process Plant, a division of Koch-Glitsch UK, provides packed tower designs for both options using very economical plastic BETA RING® random packing. The low pressure drop of this packing reduces operating costs while the good liquid phase mass transfer performance reduces capital expenditure. Additional deaeration applications include soft drink production, beer brewing, potable water treatment, boiler feed, and volatile organic compound removal. 10
BETA RING #2 BETA RING #3 KGa BETA RING BETA RING #1 11
INTALOX® SNOWFLAKE® random packing Versatile standard packing with good capacity and low pressure drop combined with higher liquid hold-up and residence time. n Superior separation efficiency and capacity n Superior performance over a wide operating range n Independent testing confirms removal efficiencies greater than 99% for groundwater air stripping n Low pressure drop reduces energy consumption in applications requiring blowers or compressors n In typical system designs, INTALOX® SNOWFLAKE® random packing can save more than 50% in energy cost compared to #1 plastic saddle n Strong shape allows deep beds for multiple transfer unit absorption n Widely used in chlorine and bromine production; environmental applications Void fraction % 97 Bulk weight lb/ft 3 3.2 (polypropylene) kg/m3 51 12
FLEXIPAC® and FLEXIPAC® HC® structured packing Excellent performance in chemically corrosive applications. Plastic FLEXIPAC® and FLEXIPAC® HC® structured packings provide the same combination of high efficiency, high capacity, and low pressure drop as their metal counterparts. The variety of plastics available makes this product suitable for some of the most demanding corrosive applications. NOTE: The wetting characteristics of plastic combined with any unique attributes of the specific material of construction may cause the actual HETP to vary significantly. Efficiency FLEXIPAC® 2Y structured packing in polypropylene (white) Plastic Structured Packing and FLEXIPAC® 500Z HC® structured packing in PFA (black). Size HETP* 500Z HC 9.8 in (250 mm) Materials of Construction Applications 1Y 11.4 in (290 mm) ■ Polypropylene ■ Air separation plant direct 2Y 19.2 in (485 mm) ■ Glass-filled polypropylene contact cooler ■ CPVC ■ Flue gas cooler 2Y HC 19.2 in (485 mm) ■ PVDF ■ Seawater scrubber 3Y 43.3 in (1100 mm) HCI absorber ■ ECTFE ■ 3X 76.8 in (1950 mm) ■ Glass-filled ECTFE ■ SO2 absorber * HETP values are estimates and are for ■ PFA ■ CI2/CIO2 scrubber reference only. Contact Kosh-Glitsch for ■ Glass-filled PFA ■ HNO3 additional information. ■ Deaerators Chlorine Dioxide Absorption Chlorine dioxide (ClO2) is a very important chemical compound used as a bleaching agent in the pulp and paper industry. ClO2 is produced by reducing sodium chlorate in a strong acid solution with a suitable reducing agent. The ClO2 gas that is discharged from the generator is fed to the bottom of a packed bed absorber where a ClO2 solution is made using chilled water. The excellent chemical resistance of plastic INTALOX® SNOWFLAKE® random packing, Super INTALOX® Saddles random packing, or FLEXIPAC® structured packing provides a lower-cost alternative to exotic metals, such as titanium. These packings are often applied in processes using CIO2 for bleaching to avoid escape in the atmosphere. 13
ETAPAK random packing Specifically designed for biological waste water treatment. The size and shape of ETAPAK random packing is designed for superior biological filtration. n The maximum exposed surface area allows growth of microorganisms and enhances biological activity, liquid distribution, oxygen transfer, and low sludge production. n The open nature of the packing and high void radius ensures flow patterns that allow continual contact between effluent, biomass, and circulating air. n The open area enhances sloughing characteristics and minimizes potential blockages. Size 120 210 Void fraction % 95 96 Dimensions in 4.5 x 3.5 1.8 x 1.6 mm 115 x 90 45 x 40 Surface Area ft2/ft3 30.5 70.0 m2/m3 100 200 Two sizes provide the ability to optimize capacity and efficiency based on application requirements. Both sizes are well suited for treatment of high strength effluents, either aerobically or anaerobically, in applications including domestic, industrial, and refinery wastes. High mechanical strength provides excellent performance in deep beds. Constructed of thermoplastic resin, the material is fully stabilized to UV light and is chemically inert. The material is non-toxic to microorganisms and is immune to fungal or bacteriological degradation. The preferred operating temperature is 32 – 194 °F [0 – 90 °C]. With the ability to remove up to 95% biochemical oxygen demand (BOD), ETAPAK 120 random packing is widely used in single- or two-stage high rate filters. It is often used for new, roughing first-stage filters where the existing plant is overloaded or underperforming. ETAPAK 220 random packing is highly effective in polishing applications and nitrification processes, including fish farming. Achieving over 85% BOD removal plus nitrification, it is frequently used on mixed industrial and domestic waste streams. Engineers at Eta Process Plant, a division of Koch-Glitsch UK, can calculate the optimum volume of media necessary and recommend the number of stages, vessel diameters, bed heights load, irrigation rates, recycle flows, and clarifier dimensions. Water treatment facility. 14
PROVALVE® Trays Plastic trays are used in a wide variety of applications, such as acid stripping, gas washing, distillation of corrosive components, and gas drying using sulfuric acid. For corrosive distillations, Koch-Glitsch plastic trays can be a more cost-effective solution than trays constructed of exotic metals or graphite. Combining plastic composites technology with fluoropolymer technology allows trays to be produced for relatively large diameter columns that operate at temperatures up to 392 °F [200 °C]. For columns with diameters less than 42 in [1066 mm], Koch-Glitsch can manufacture trays in cartridge-style construction. Koch-Glitsch supplies bubble cap, tunnel cap, sieve, and PROVALVE® valve trays in plastic materials. The PROVALVE unit (pictured) is also available in fluoroplastics and graphite for highly corrosive applications where a suitable metallic material is not available. PROVALVE trays are used in a wide variety of services – from severely fouling refinery applications to petrochemicals to fine chemical separations. PROVALVE® tray in PTFE material. Mist Eliminators When vessel size is not set by the mist eliminator, the practical starting point is often the knitted wire mesh mist eliminator. DEMISTER® mist eliminators provide high separation efficiency with a low pressure drop at the lowest installed cost. They are custom manufactured to any size and shape from a wide selection of plastics and fluoroplastics to perform in corrosive environments. FLEXICHEVRON® mist eliminators are characterized by smooth blade profiles and wide blade spacing that provide additional fouling resistance. Koch‐Glitsch offers an extensive line of FLEXICHEVRON mist eliminators to meet the demanding requirements of applications where undissolved solids can be present or droplets can be sticky or viscous. Vapor flow paths that are more open provide higher capacity and lower pressure drop than other mist eliminators. They are a good selection for use in scrubbers, cooling towers, and evaporators. FLEXIFIBER® mist eliminators are applied to achieve high efficiency removal of sub-micron liquid droplets. Typical applications include sulfuric acid, chlorine, and turbine lube oil tank vents. Plastics, fluoroplastics, and FRP materials are available for element (cage) construction. In most process industries, it is common for two immiscible liquids to mix with each other to create a dispersion. Products such as KY-FLEX® liquid-liquid settling media and KY-MESH liquid-liquid coalescing Left (FLEXIFIBER® mist eliminators), center (DEMISTER® mist media are applied to separate the liquids. Both products eliminators), and right (FLEXICHEVRON® mist eliminators). are available in plastic and fluoroplastic materials. Refer to the Koch-Glitsch brochure, Mist Elimination – Liquid-Liquid Coalescing (MELLC-01), for more information on Koch-Glitsch mist elimination and separation technologies. 15
Koch-Glitsch Corporate Offices Worldwide Headquarters Koch-Glitsch, LP 4111 East 37th Street North Wichita, KS 67220 – United States tel: 316-828-5110 fax: 316-828-7985 Europe Koch-Glitsch Italia S.r.l. Via Torri Bianche, 3A 20871 Vimercate MB – Italy tel: +39-039-638-6010 fax: +39-039-638-6011 Asia Koch Chemical Technology Group Singapore Pte. Ltd. 260 Orchard Road, #11-01/09 Singapore 238855 tel: +65-6831-6500 fax: +65-6835-2031 The Heeren Koch-Glitsch (a division of Koch Chemical Technology Group India Pvt. Ltd.) Seawoods Grand Central Navi, Mumbai - 400 706 F901 to F904, Tower-2 tel: +91-22-6771-7171 fax: +91-22-6771-7161 Maharashtra - India Nerul Road, Nr. Seawoods Railway Station For a complete list of our offices and facilities, visit us on the Web at www.koch-glitsch.com. Emergency Numbers United States/Latin America: 1-888-KOCH-911 (mass transfer), 1-316-207-7935 (mist elimination), or your local Koch-Glitsch office. Canada: 1-905-852-3381 (Uxbridge, Ontario). Europe/Middle East/Africa: +39-06-928-911 (Italy), +44-1782-744561 (United Kingdom), or your local Koch-Glitsch office. Asia: +65-6831-6500 (Singapore) or your local Koch-Glitsch office. Trademarks Patents The following registered trademarks are owned by Koch-Glitsch, LP in the The following technologies are protected by one or more patents United States and may be registered in other jurisdictions: BETA RING® random in the USA; other foreign patents may be relevant: FLEXILOCK® packing, CASCADE MINI-RINGS® random packing, DEMISTER® mist eliminator, tray construction (US6592106), FLEXIPAC® HC® structured packing FLEXICHEVRON® mist eliminator, FLEXIFIBER® mist eliminator, FLEXIPAC® structured (US5632934, US6478290), INTALOX® ULTRA random packing (US7722945), packing, FLEXIPAC® HC® structured packing, FLEXIRING® random packing, KFBE fluidized bed structured packing (US6224833), Model 758 INTALOX® Packed Tower Systems technology, INTALOX® Saddles random Enhanced Vapor Horn (US5605654, US5632933, US6889961, US66889962, packing, INTALOX® SNOWFLAKE® random packing, KG-TOWER® software, US7104529), PROFLUX® severe service grid (US8298412), PROVALVE® tray KOCH-GLITSCH®, “K” KOCH-GLITSCH (logo), KY-FLEX® liquid-liquid coalescing (US5762834), and SUPERFLUX® tray (US5895608). Available exclusively media, and PROVALVE® tray. The following trademarks are owned by Koch- from Koch-Glitsch, FLEXIPAC® HC® structured packing is protected by Glitsch, LP in the United States and may be registered in other jurisdictions: US Patent 5,632,934 and other patents worldwide assigned to Praxair ETAPAK random packing, KY-MESH liquid-liquid coalescing media, and YOU CAN Technology, Inc. Koch-Glitsch, LP is the exclusive worldwide licensee of RELY ON US. All other trademarks, service marks, or registered trademarks that Praxair Technology, Inc. for the manufacture and sale of this packing appear in this document are the trademarks or service marks of their respective in all markets except for industrial gas separation. owners. Legal Notice For related trademark information, visit http://www.koch-glitsch.com/trademarks. The information contained in this bulletin is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee of performance. Bulletin KGPPCI-1. Rev. 05-2018. Printed in USA. © 2018 Koch-Glitsch, LP. All rights reserved.
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